Polymer electrolyte membrane fuel cells (PEMFC) are the most promising power sources for various portable electronic devices that operate at low temperature in between 70-80°C. Bipolar plate, an important component of PEMFC contributes nearly 80% weight of the total weight of fuel cell and 50% of the total cost of fuel cell stack. Worldwide efforts are going on to develop strong and thin bipolar plate. This book described the development of Low Density and Low Cost Expanded Graphite (EG) Based Composite Bipolar Plate for PEMFC. (EG) synthesized from different flake size of natural graphite using chemical oxidation and thermal treatment has loose structure and porous behavior which endows high surface area. The composites bipolar plates are developed from EG and phenolic resin in different wt. percentages ratio. The composites with EG ranges from 40-50 wt. % are suitable for achieving the desired electrical and mechanical properties of PEMFC